Noncircular replaceable fuel filter elements and systems including the same

ABSTRACT

One embodiment is a filter assembly wherein the shape of the filter is a non-circular geometry. Other embodiments include unique apparatus, devices, systems, and methods to remove contaminates from a flow of fuel while at the same time providing a unique filter and filter assembly geometry. Further embodiments, forms, objects, features, advantages, aspects, and benefits of the present application shall become apparent from the detailed description and figures included herewith.

FIELD OF THE INVENTION

The present invention relates generally to filter elements and moreparticularly, to noncircular replaceable filter elements and systemsincluding the same.

BACKGROUND

Fuel filters are found in almost all modern internal combustion enginesin one form or another. A fuel filter is a filter that is placed at somepoint in the fuel line and is designed to remove unwanted contaminatesor particulates from the supply of fuel. If these contaminates are notremoved before the fuel enters the engine, they can cause rapid wear andfailure of such items as fuel pumps, injectors, and cylinders due to theabrasive action of the particles on high-precision components. Fuelfilters also can improve performance of the engine, as the lesscontaminants in the fuel, the more efficiently it can be burned. In manypotential engine system designs space constraints would not allow for aconventional circular filter element.

SUMMARY

One embodiment is a filter assembly wherein the shape of the filter is anon-circular geometry. Other embodiments include unique apparatus,devices, systems, and methods to remove contaminates from a flow of fuelwhile at the same time providing a unique filter and filter assemblygeometry. Further embodiments, forms, objects, features, advantages,aspects, and benefits of the present application shall become apparentfrom the detailed description and figures included herewith.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view of an exemplary fuel filter assembly.

FIG. 2 is a front view of FIG. 1.

FIG. 3 is a side view of FIG. 1.

FIG. 4 is a perspective view of an exemplary fuel filter cartridge.

FIG. 5 is an alternate perspective view of FIG. 4.

FIG. 6 is a cross-sectional view of FIG. 4.

FIG. 7 is a cross-sectional view of an exemplary filter media.

DETAILED DESCRIPTION

For the purposes of promoting an understanding of the principles of theinvention, reference will now be made to the embodiment illustrated inthe drawings and specific language will be used to describe the same. Itwill nevertheless be understood that no limitation of the scope of theinvention is thereby intended, such alterations and furthermodifications in the illustrated device, and such further applicationsof the principles of the invention as illustrated therein beingcontemplated as would normally occur to one skilled in the art to whichthe invention relates.

With reference to FIGS. 1-3, there is illustrated a fuel filter assembly100 including a housing 102 and a lid 104 removably connected with anupper portion of the housing 100. Housing 102 includes an upper segmentor portion 106, a central segment or portion 108, and a lower mountingsurface segment or portion 110. In one embodiment, upper portion 108 ofhousing 102 has a generally circular cross-section shape and centralportion 108 has a generally non-circular cross-section shape. The lowermounting surface portion 110 of housing 102 has ends that includepartially circular shaped recessed portions 112 which provide space forfluid connections to be connected with filter assembly 100.

The upper portion 106 of housing 102 includes a shelf portion 114 thatis defined at a point where the upper portion 106 of housing 102transitions into central portion 108 of housing 102. As illustrated,shelf portion 114 of housing 102 extends outwardly from the non-circularcentral portion 108 of housing 102 a predetermined distance. The shelfportion 114 includes a fuel inlet port 116 and a fuel outlet port 118.In the illustrated example, fuel inlet port 116 and fuel outlet port 118are located at opposite sides of shelf portion 114 of housing 102.

Fuel inlet port 116 and fuel outlet port 118 are positionedsubstantially parallel in relation to a vertical axis of housing 102.The non-circular cross-sectional shape of central portion 108 of housing102 provides extra space under upper portion 106 of housing 102. Thisextra space is used for fluid connection ports 116, 118. A fuel supplyline 120 is connected with fuel inlet port 116 in a vertical directionor orientation in relation to the vertical axis of the housing 102. Fuelsupply line 120 is used to supply fuel or fluid to filter assembly 100.Fuel enters filter assembly 100 through fuel supply line 120 where it isfiltered by filter assembly 100, and the filtered fuel then exits filterassembly 100 through fuel outlet port 118.

In one embodiment, a fuel regulator valve 122 is connected with fueloutlet port 118. Fuel regulator valve 122 is designed to open at apredetermined pressure level, for example 60 PSI, so that fuel will onlyexit filter assembly 100 through fuel outlet port 118 once apredetermined amount of pressure exists in filter assembly 100. Fuelregulator valve 122 is connected with a fuel or fluid return line 124.Although not illustrated, return line 124 may be in fluid communicationwith a fuel tank or reservoir or an engine. As with fuel supply line120, fuel regulator valve 122 and fuel return line 124 are connectedwith fuel outlet port 118 in a vertical direction or orientation inrelation to the vertical axis of housing 102.

The exemplary non-circular cross-section shape of the central portion108 of housing 102 provides extra space under upper portion 106 ofhousing 102 thereby allowing fluid connections to be connected to filterassembly 100 in a vertical direction. This provides vertical access tofluid lines which allows filter assembly 100 to be positioned inlocations having tight tolerances or minimal space. As illustrated, fuelor fluid connections 120, 124 run vertically down filter assembly 100through partially circular shaped recessed portions 112 of ends of lowermounting surface portion 110 of housing 102.

The non-circular cross-sectional configuration of central portion 108 ofhousing 102 is further illustrated in FIGS. 2 and 3. A front view offilter assembly 100 is depicted in FIG. 2 and a side view of filterassembly 100 is depicted in FIG. 3. Upper portion 106 of housing 102 isconfigured having a generally circular cross-sectional configuration orshape. Central portion 108 of housing 102 is configured having agenerally non-circular cross-sectional configuration or shape. In theillustrated example, central portion 108 has a generally oval orelliptical cross-sectional configuration or shape.

Referring collectively to FIGS. 4 and 5, filter assembly 100 includes areplaceable filter cartridge 200 that is positioned within an interiorportion of housing 102. Filter cartridge 200 includes a top endplate202, a filter media 204, and a lower endplate 206. Top endplate 202 hasa generally circular configuration or shape and has a lower surface 208that is connected with an upper end 210 of filter media 204. Thediameter of circular shaped top end plate 202 is larger than the overallcross-sectional size of filter media 204 such that peripheral edge 212of top end plate 202 extends beyond the outer edges or periphery offilter media 204.

Filter media 204 has a generally oval or elliptical cross-sectionalconfiguration or shape that generally matches the configuration or shapeof central portion 108 of housing 102. In one form, filter media 204comprises a meltblown media, an air-laid media, a wet-laid media or asynthetic blend of one or more of the media types. Lower end plate 206has a generally oval or elliptical cross-sectional configuration. Lowerend 214 of filter media 204 is connected with an upper surface of lowerend plate 206. Lower end plate 206 also includes aperture 216 located atapproximately the center of lower end plate 206. Seal 218 is positionedaround aperture 216. As set forth in greater detail below, filtercartridge 200 can be removably positioned in a fluid chamber defined bythe interior of housing 102.

Referring to FIG. 6, a cross-sectional view of filter assembly 100 isillustrated. Upper portion 106 of housing 102 defines first fluidchamber 300 and central portion 108 of housing 102 defines second fluidchamber 302. First fluid chamber 300 is generally cylindrical orcircular in shape and transitions into second fluid chamber 302, whichhas a generally non-circular shape or configuration. First and secondfluid chambers 300, 302 house filter cartridge 200. Filter media 204 offilter cartridge 200 is spaced apart from internal wall 303 of upperportion 106 and central portion 108 of housing 102 a desired distance.

Lower mounting surface portion 110 of housing 102 and lower end plate206 of filter cartridge 200 define a third fluid chamber 304, which isillustrated as having a generally non-circular shape. In the illustratedexample, a smooth transition is illustrated between third fluid chamber304 and second fluid chamber 302. As such, third fluid chamber 304generally has the same shape as second fluid chamber 302. However, inalternative forms, third fluid chamber 304 may take many different formsor shapes such as, for example, oval, elliptical, circular, square,rectangular and so forth. In some fluid applications, such as dieselfuel for example, third fluid chamber 304 provides a location in whichwater that is removed from the fuel may be collected. A small space orgap 305 is located between the outer edge of lower end plate 206 andinternal wall 303 of central portion 108 of housing 102 that allowswater to travel to third fluid chamber 304. Although not illustrated, alower end of lower mounting surface portion 110 may include a valve thatallows a user to drain water that has been removed from the fuel fromthird fluid chamber 304.

A lower surface 306 of the lower mounting surface portion 110 of housing102 includes a connection member 308. As illustrated, the connectionmember 308 protrudes upwardly a predetermined distance from lowersurface 306 of lower mounting surface portion 110. Connection member 308is circular in shape in the illustrated example, but may be formedhaving other shapes in alternative forms. Lower mounting surface portion110 includes at least one aperture 310 running through the outer edgesof a mounting segment or portion 312 of lower mounting surface portion110. Aperture 310 allows filter assembly 100 to be connected with avehicle by a bolt or another equivalent connection device.

Filter assembly 100 also includes a center post 314 that protrudesupwardly along a vertical axis from connection member 308. In theillustrated form, center post 314 protrudes up through second fluidchamber 302 defined by central portion 108 of housing 102 and into firstfluid chamber 300 defined by upper portion 106 of housing 102. Centerpost 314 includes hollow interior 316 and at least one aperture 318located on upper portion 320 of center post 314. Aperture 318 allowsfluid that has been filtered by filter media 204 to pass into hollowinterior 316 of center post 314. Lower portion 322 of center post 314includes an externally threaded segment 324 that is used to securecenter post 314 to an internally threaded segment 326 of connectionmember 308. Lower portion 322 of center post 314 could be secured toconnection member 308 using various other connection methods.

Filter cartridge 200 is fixedly secured in housing 102 by placingaperture 216 of filter cartridge 200 on upper portion 320 of center post314 and forcing filter cartridge 200 downwardly until seal 218 of lowerend plate 206 makes contact with upper portion 328 of connection member308. Seal 218 provides a fluid tight seal between lower end plate 206and center post 314. As illustrated, lower end plate 206 includes anupwardly extending circular shaped rib 330 that defines aperture 216 oflower end plate 206. Seal 218 is connected with lower surface 332 oflower end plate 206, outer surface 334 of the rib 330, and upper surface336 of rib 330. As previously set forth, lower surface 336 of lower endplate 206 and lower surface 306 of lower mounting surface portion 110define third fluid chamber 304. In alternative forms, center post 314may include a connection member that provides a fluid tight seal withlower end plate 206.

As further illustrated in FIG. 6, the filter cartridge 200 includes acentertube 340. Centertube 340 runs substantially parallel with filtermedia 204 and housing 102 along a vertical axis of filter assembly 100.Centertube 340 includes a plurality of apertures 342 that allow fuel topass into an internal fluid chamber 344 of filter cartridge 200.Filtered fluid from internal fluid chamber 344 may then enter hollowinterior 316 of center post 314 through apertures 318 in center post314. An upper surface of lower end plate 206 is connected with a lowerend of centertube 340 and a lower surface of upper end plate 202 isconnected with an upper end of centertube 340. Filter media 204 iswrapped, positioned, or otherwise connected around or with the outsidesurface of centertube 340.

Lid 104 is removably connected with upper portion 106 of housing 102.Once filter cartridge 200 is placed over center post 314, lid 104 maythen be connected with upper portion 106 of housing 102. In one form,lid 104 includes an externally threaded segment 346 that screws into aninternally threaded segment 348 of upper portion 106 of housing 102. Theexternally threaded segment 246 of lid 104 is located on lower portion350 of lid 104. The outside diameter of lower portion 350 of lid 104 issomewhat smaller than the inside diameter of upper portion 106 ofhousing 102.

A central portion 352 of lid 104 includes a retaining clip 354 and anupper internal surface 356. Retaining clip 354 protrudes downwardly apredetermined distance from upper internal surface 356. As lid 104 isscrewed into upper portion 106 of housing 102, upper end plate 202 offilter cartridge 200 snaps or passes through retaining clip 354. As lid104 continues to be screwed into upper portion 106 of housing 102, upperend plate 202 of filter cartridge 200 eventually makes contact withupper internal surface 356 of lid 104. Center post 314 and lid 104thereby cooperate with one another to securely hold filter cartridge 200within first and second fluid chambers 300, 302 defined by housing 102.In alternative forms, lid 104 may be secured to upper portion 106 ofhousing 102 using a quarter turn lid (bayonet), a friction fit, or theillustrated threading arrangement could be reversed.

A seal 358 is positioned within a groove or notch 360 of lid 104 and isused to form a fluid tight seal between an outside edge 362 of lid 104and an inside edge 364 of upper portion 106 of housing 102. Referringback to FIGS. 1-3, lid 104 includes a dome shaped cap portion 150 thatincludes a plurality of gripping members 152 protruding upwardly fromthe dome shaped cap portion 150. At the top of dome shaped cap portion150 is a tool attachment member 154. Gripping members 152 allow aninstaller to use their hands to begin to tighten lid 104 onto housing102 and after reaching a certain tightening point, a tool may be placedon tool attachment member 154 to further tighten lid 104 on to an upperedge 156 of upper portion 106 of housing 102.

Referring to FIG. 7, a top cross-sectional view of a portion of filtermedia 204 of filter cartridge 200 is illustrated. As depicted, filtermedia 204 has a predetermined width 204 a and a predetermined height 204b. In addition, filter media 204 has a non-circular shape, which isillustrated as being oval or elliptical shaped in this form. In oneform, the oval size is such that the ratio of predetermined height 204 bin relation to predetermined width 204 a is 0.9 or less. Central portion108 of housing 102 and center tube 340 have a similar size configurationas well as shape.

While the invention has been illustrated and described in detail in thedrawings and foregoing description, the same is to be considered asillustrative and not restrictive in character, it being understood thatonly the preferred embodiments have been shown and described and thatall changes and modifications that come within the spirit of theinventions are desired to be protected. It should be understood thatwhile the use of words such as preferable, preferably, preferred or morepreferred utilized in the description above indicate that the feature sodescribed may be more desirable, it nonetheless may not be necessary andembodiments lacking the same may be contemplated as within the scope ofthe invention, the scope being defined by the claims that follow. Inreading the claims, it is intended that when words such as “a,” “an,”“at least one,” or “at least one portion” are used there is no intentionto limit the claim to only one item unless specifically stated to thecontrary in the claim. When the language “at least a portion” and/or “aportion” is used the item can include a portion and/or the entire itemunless specifically stated to the contrary.

1-20. (canceled)
 21. An apparatus, comprising: a filter element suitablefor filtering fuel having a substantially ellipsoid planar sectionnormal to a major axis; a first endplate coupled to the filter elementand having a substantially ellipsoid shape, the first endplate furtherincluding an aperture; and a second endplate coupled to the filterelement, the second endplate being solid with no aperture and having aperipheral edge defining a substantially circular shape.
 22. Theapparatus of claim 21, further comprising a centertube coupled to one ofthe first endplate and the second endplate.
 23. The apparatus of claim22, wherein the centertube has a substantially ellipsoid planar sectionnormal to the major axis.
 24. (canceled)
 25. The apparatus of claim 21,further comprising a seal mounted to the first endplate and disposedabout the aperture.
 26. The apparatus of claim 22, wherein thecentertube extends substantially parallel with the major axis from thefirst endplate to the second endplate and has a first end connected withthe first endplate and a second end connected with the second endplate.27. The apparatus of claim 21, wherein the first endplate includes a ribprotruding towards the second endplate that defines the aperture in thefirst endplate.